Auxiliary Power Consumption
Auxiliary Power Consumption
Auxiliary Power Consumption
and also consumes a substantial amount of energy in the form of auxiliary consumption required for various plant equipments and services
Operating the equipments at maximum efficiency and Reduction of auxiliary Power consumption
depending on Size of plant ,use of TDBFP &age of plant The 500 MW units register the least APC, largely due to the incorporation of TDBFP. In some of the old 110 MW plants, APC consumption of 14% is also observed. Energy audit in a vast thermal power station (TPS) is better tackled when the thermal power plant operations are segregated into different sub-areas like: main plant auxiliaries, draft system (consisting of ID/FD/PA fans), feed water system [consisting of Boiler Fed Pumps (BFPs) / Condensate Extraction Pumps (CEPs), Circulating Water (CW) system-including Cooling Tower (CTs)], and off sites (consisting of coal handling plants, ash handling plants, air compressors, AC plants, station lightings etc.).
Power Plant is major source of energy consumption. During the financial year 2007-08 total generation by coal plant was 488157.46 MUs with PLF 78.75. Auxiliary Power Consumption was 8.17%. If this APC gets reduced only by 0.17% then it is equivalent to fresh capacity addition of 120 MW without any investment.
auxiliary power consumption (4.30%) in the country. Among Central Sector Stations, Talcher STPS of NTPC achieved the lowest auxiliary power consumption (5.34%).
Among State Sector Stations, Chandrapur STPS of MAHAGENCO achieved the lowest auxiliary power consumption (7.40%). Among different capacity groups, the lowest auxiliary power consumption was 6.13% in 500 MW group.
Motor details requiredID code, Application, Make, Brief details of driven equipment, Type of the Motor, Motor kW, Motor frame, Duty, Rated RPM, Rated p.f., Rated motor efficiency ,Motor make, Motor voltage, Rated current of motor, Year, Operating hours, Energy meter installed or Not times the motor is rewound
, No. of
Collect the above information for all motors to be covered in the energy audit. Collect the motor efficiency curves
such as kW, kVA, pf, V, A and Hz Infrared pyrometer (In case any heating of cable or motor is suspected) Stroboscope: To measure the speed of the driven equipment and motor The above instruments can be used in addition to the calibrated online / plant instruments
/yearly consumption if available) Motor electrical parameters (kW, kVA, Pf, A, V, Hz, etc.) for individual motors Equipment operational details
While conducting the measurement or performance
evaluation of any system simultaneously, the following need to be noted Unit load of the plant Date & time of measurement Instruments used for measurement Frequency of the measurement
System details
Detailed interactions with the plant personnel
Air Compressors Coal Handling Plant Raw Water pumps DM water pumps A/C systems ESP Total
Boiler Feed Pump Condensate extraction Pump CW Pumps ID Fans FD Fans PA Fans Mils CT Fans
Total Generation Auxiliary Power Consumption Contribution To APC By Unit 1 % 2.78 0.26 0.22 1.38 1.41 0.74 0.35 0.29 0.26 2.37 Unit 2 MW 4.29 0.43 0.31 2.08 2.38 1.53 0.57 0.47 0.42 4.21
MW 1305.57 111.7 Unit 3 MW 4.52 0.41 0.30 2.34 2.36 1.69 0.57 0.47 0.42 4.11 % 3.39 0.31 0.23 1.51 1.52 1.08 0.36 0.30 0.27 2.64 Unit 4 MW 1.69 1.21 8.18 4.85 2.92 1.11 0.52 0.38 10.28
% 81.60 (of installed capacity) 8.56 (of actual generation) Unit 5 MW 1.78 1.26 7.25 4.82 2.92 1.11 0.52 0.38 10.22 % 0.42 0.29 1.51 1.00 0.61 0.23 0.11 0.08 2.13 Over All MW 13.34 4.73 3.43 22.12 16.72 10.25 3.92 2.45 2.04 32.70 % 1.02% 0.36% 0.26% 1.69% 1.28% 0.79% 0.30% 0.19% 0.16% 2.50%
MW BFP's 4.52 CEP's 0.43 FD's 0.35 ID's 2.26 PA's 2.31 Coal Mills 1.21 CHP 0.57 AHP 0.47 Air 0.42 Compressors Others 3.89 (CWPs, RWPs, DM Plant, etc ) Total 16.42
% 2.98 0.30 0.22 1.44 1.65 1.06 0.39 0.33 0.29 2.92
10.06
16.67
11.58
17.18
11.61
31.14
8.53
30.26
6.38
111.70
8.56%
Details Rated Kw Rated Efficiency Rated Speed Measurement of parameters Power factor kVA KW drawn Frequency Harmonics Motor speed Driven Voltage Current Power equipment speed Driven equipment parameters Operational observations Transmission % loading on the motor
Loading =
Input kW to motor x 100 --------------------------------------------------------------------Name plate kW /Name plate full load motor efficiency
parameters such as speed, load, pressure, temperature, etc., (as relevant) are also taken
correction & energy meters for monitoring is also looked into for each case.
Capacitors connected in parallel (shunted) with the motor are typically used to improve the power factor
The impacts of PF correction include reduced kVA drawn , KVAR & current, reduction of transformer load, Reduction of cable losses, reduction of switch gear rating, Enhanced life of equipment
MEASURES
Replacement / sizing of motors Opting for energy efficient motors, Use of high efficiency motors, Use of energy efficient transmission Replacement of pulleys Direct coupling
o
o
The BIS standards specify that a motor should be capable of delivering its rated output with a voltage variation of 6 % and frequency variation of 3 %. Motor o Identified motors with less than 50 % loading, 50 75 % loading, 75- 100 % loading, over 100 % loading o Identified motors with machine side losses / inefficiencies like idle operations, throttling/damper operations o Motor load survey is aimed not only as a measure to identify motor efficiency areas but equally importantly, as a means to check combined efficiency of the motor, driven machine and controller
Operating only 4 mills instead of 5 mills in 210 MW units Shutting of CTs cells in conjunction with favorable weather
conditions and replacing existing aluminum cast and GRP blades with FRP
avoiding idle running of conveyors & crushers
Air in-leaks in draft system (O2 measurement) blanketing Replacement of inefficient BFPs as a part of R& M of the old plants. Clipping of one stage from the multi stage BFPs to balance the pressure drop requirements between HP heaters, economizer and boiler drum etc. Use of higher pressure in the deareator to commensurately reduce BFP power consumption (reduced head developed) Running of two CEPs instead of 3 CEPs (3 CEPs are run to avoid tripping due to lower frequency in some of the power plants) Application of variable speed drives Installation of hydraulic turbine instead of feed regulating section to avoid pressure drops and to generate additional power